Section 1: Introduction

Transcription

1 Section 1: Introduction Welcome to the world of STAR TRAC. In your hands is the STAR TRAC TR 4500 Service Manual. This manual is designed to be easy to use, providing detailed instructions on how to service and maintain the TR We highly recommend that you read all the applicable sections of the service manual prior to serving the treadmill. The information on the following pages will enable you to begin easily, quickly, and safely. Contents 1.1 How to use the Service Manual 1.2 Precautions 1.4 Tools and Test Equipment 1.5 Treadmill Overview. 1.3 Product Support Assistance 1.0

2 How To Use This Manual This Service Manual has been written to assist and instruct the repair technician on key components for quick and efficient diagnosis of service problems. To assist in finding the applicable sections in the Service Manual. Each Section has a table of contents to help locate specific symptoms and topics. Titles and major headings are located at the top of every page. This manual is to be used strictly as a Maintenance manual for service and repair, not as an owner s manual. An illustrated Parts List is located at the back of this manual for identifying parts with part numbers. Troubleshooting tables and Error Code Flowcharts are included for certain sections to help diagnose the system problem and find the root cause. 1.1

3 Precautions 1. Always make sure that the treadmill is turned off and unplugged before starting any work, unless otherwise noted, or when necessary for voltage testing. 2. Read each section through for NOTES before starting any work. 3. To pull apart electrical connectors, pull on the connector itself, not the wires. 4. When replacing fuses, be sure the new fuses is the correct amperage rating. Do Not exceed the fuse amp rating. If necessary use a fuse of lower rating until the proper fuse may be attained. 5. When checking continuity at the wire connector, insert the test probe carefully to prevent the terminals from bending. 1.2

4 Product Support Asistance PRODUCT SUPPORT DEPARTMENT STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assistance World Wide. Providing superior product support and customer service is at the very heart of STAR TRAC s business philosophy. This commitment to service has been a major contributor to STAR TRAC s success and growth in the worldwide fitness equipment industry. Technical Assistance When purchasing a part or requesting technical assistance, please contact our Product Support Department : CALL TOLL-FREE: or US and CANADA or When placing the call, please have the following information available: 1. STAR TRAC model. 2. STAR TRAC serial number 3. Problem statement / symptom. After Hours Voic Direct CALL TOLL-FREE: When placing the call, please have the following information available: 1. STAR TRAC model. 2. STAR TRAC serial number 3. Problem statement / symptom. 4. Return phone number and contact name. Fax Requests Domestic and International: Fax When placing the fax, please supply the following information: 1. STAR TRAC model. 2. STAR TRAC serial number 3. Problem statement / symptom. 4. Return phone fax number and contact name. 5. Purchase order or reference number. 6. Part description and quantity. 7. Ship to/bill to. Product Support Documentation Access Web page Docufacts CALL TOLL FREE ext. 640 US and Canada or for a list Product Support Procedures and Bulletins. 1.3

5 Tools and Equipment Equipment Philips Head Screwdriver #2 Small Slotted Screwdriver 3/32 Bungee Cord 28 Function Shroud Motor Control Board Assembly Side Bed Cover and End Caps Auto-Transformer Motor Control Potentiometers (MAX SPD) & (IRCOMP) Suspend Motor Shroud on Display Rail 5/32 Hex Allen key Handrail assembly 5/64 Hex Allen key Display Board set screws 1/8 Hex Allen key Display Assembly 1/4 Hex Allen key Running Belt Head Roller Tail Roller 5/16 Wrench or Nut Driver Drive Motor Bolts 9/64 Allen Wrench Elevation Motor 17-mm Socket Wrench Multi-meter Voltage Checks Continuity / OHM ΩChecks 1.4

6 Treadmill Overview DC POWER SUPPLY The MCB provides power to the display assembly. Establishes a reference voltage and potentiameter position from the elevation motor RUNNING BELT MOTOR DRIVE CONTROL Takes Alternating Current and converts it to Pulse Width Modulation (PWM) to power the Drive Motor. Motor voltage feedback and control-speed-commands determine the level of PWM power delivered to the motor. Motor Control circuits include fault sensing and safety functions. TACHOMETER SIGNAL CONDITIONING The signal from the RPM sensor is fed to signal conditioning circuits on the MCB, where the signal is converted to a digital output that is utilized by the Display Assembly to indicate belt speed. ELEVATION MOTOR CONTROL The elevation circuit on the MCB receives elevation direction and enable information from the Display Assembly, using these signals to provide control to the Elevation Motor. Elevation position information, in turn, is fed to the Display Assembly to indicate percent of incline. 1.5

7 Section 2: Preventive Maintenance Schedules Performing regular preventive maintenance on all Star Trac treadmills is strongly recommended. Without preventive maintenance, normal wear and tear may cause cumulative effects, such as misalignment and early replacement of parts. This may result in downtime. For this reason, we highly recommend following the manufacturer s maintenance schedules. 2.1 Preventative Maintenace Chart 2.2 Waxing Procedure Contents: 2.0

8 Preventive Maintenance Chart Maintenance Clean Inspect Lubricate Replace Daily Weekly Monthly Quarterly Using a liquid non-abrasive cleaner, wipe down the following: display board handrails, shroud, heart rate grips. Note: Do not spray directly onto the display board or heart grips. Elevate the treadmill and vacuum under the unit. Note: Unplug the unit when vacuuming. Lift the motor shroud and vacuum around the motor and electronics. Clean and lubricate the elevtion screws. Note: This must be done with the unit unplugged and turned off. Inspect for wear and tear on exterior parts regularly, especially under the running belt. Inspect the linecord plug and cord for possible damage or loose connection. Verify running belt alignment and tension. Inspect the area under the treadmill for obstructions. Inspect the display and handrail screws for loosening. Inspect the display panel keys for wear. Using a silicone spray lubricate the elevation screws, while the unit is elevated. Note: This must be done with the unit unplugged and turned off. Wax the running belt and deck using Unisen powder wax. 2.1

9 Note: Apply wax powder while belt and deck are still warm (from 5 to 15 minutes of use) for optimum benefit. The following steps are done with the treadmill off. Quarterly Waxing The treadmill is designed with an automatic prompt, which will display RE WAX across the display screen every 2,000 miles or 3,000 kilometers. The procedure below explains step-by- step how to apply wax and clear the RE WAX prompt. Time Required: 5 minutes Tools Required: 1 Wax Powder Bag (Unisen) Teaspoon 1 Clean Towel Paint Stick or Yard Stick Diluted All-purpose Cleaner (409) Bristle Brush PROCEDURE STEP 1: Cleaning the deck and belt: Using the stick or ruler, slide a towel under the middle of the running belt from one side of the frame to the other. Hold the edges of the towel, pull from head-roller down to the tailroller, then pull the belt down to wipe the remaining of the belt. TIP: Careful when removing the towel, it will be dirty. Fold the dirty towel and shake into trash. STEP 2: Re-waxing the deck and belt: Lift the left side (facing the display) of the belt, about 12 inches down from the motor shroud (see above figure). Hold the belt up such that the width of the belt is elevated from the deck. Gently place one level teaspoon of wax powder on the deck about two inches from the edge, and blow the wax steadily under the belt, so that the wax powder is spread evenly across the deck (see above figure). Gently place a second level teaspoon of wax 18 inches down the belt. Repeat the above step to the right side of the belt and deck. STEP 3: Walking the wax in: Start the treadmill at 1 mph and walk on all sections of the belt and deck for 1 minute to ensure the wax has been evenly distributed and worked-in properly. Note: Blow away extra wax first from around the siderails and deck before wiping. Note: The RE WAX prompt may be cleared either in Settings or Configure Mode. STEP 4: Clean-up: Remove any excess wax with diluted cleaner (409) and towel, or bristle brush. STEP 5: Clear RE WAX prompt: Engage Settings or Configure Modes. Press and hold the 0, 1 or(2) & START keys down, release the 1 or (2) key only. Display will beep and display SETTINGS or CONFIGURE momentarily (depending if the 1 or 2 key was released), then UNITS will be displayed. Press the Incline Down Key (elevation) until LSTDCK is displayed. Press and release the HEART Key, this will automatically transfer the accumulated miles/kilometers into the LSTDCK, press the ENTER Key to save. 2.2

10 Section 3: Diagnostics The STAR TRAC 4500 Treadmill series contains diagnostic and customizing modes. In these modes you are able to check accumulated data about the past usage of the treadmill, test its motor and display controls, and investigate display code messages. For these reasons, your treadmill is equipped with a ; Manager Mode (customize) Maintenance Mode (diagnostics) Motor Test Mode (diagnostics) Display Test Mode (diagnostics) Heart Rate Test Mode (diagnostics) 3.1 Engaging Manager Mode 3.2 Engaging Maintenance Mode 3.3 Description of parameters Contents: 3.8 Engaging Motor Test Mode 3.9 Calibration 3.10 Engaging Display Test Mode Heart rate test 3.0

11 Manager Mode After having used you Star Trac 4500 treadmill for several workouts, you may wish to specially customize your treadmill by changing some of its settings. To engage Manager Mode: 1. Press and hold the 0, 1 & START keys together. While holding the 0 & START keys down, release the 1 key only. 2. The display will beep and display Manager Mode momentarily, then UNITS will be displayed. Once the treadmill is in Manager Mode, you may use the following keys: INCLINE KEY: Displays the next or previous parameter. SPEED KEYS: Allows the variable to be changed within the parameter. ENTER KEY: Saves the value if changed in the EPROM (software). Note: ENTER KEY must be pressed, for each value changed. STOP KEY: Exists Manager Mode and restarts the treadmill with a warm start. 0 9 KEYS: Enters new parameter values. If UNITS parameter is displayed, key 5 starts DISPLAY TEST and key 8 starts MOTOR TEST. HEART HEART KEY: When pressed will automatically display manufactures default value. Note: ENTER KEY must be pressed, to save the default values if changed. 3.1

12 Manager Mode The following parameters may be changed using the previous keys: Parameters Lowest Value Highest Value Option 1 Option 2 Default Value Meaning UNITS English Metric English English= units of lbs., miles, hours, minutes Metric= units of kg., km, hours, minutes. MN SPD English=0.5 Metric= Minimum speed in MPH or KM/HR MX SPD English=10.0 Metric= Maximum speed in MPH or KM/HR EL OPT ON OFF ON Turns the elevation system ON or OFF. TIME Maximum time in minutes allowed for program, including warm-up/cool-down. OP HRS ,553.5 Total operating hours DIST ,635 Total treadmill miles (Units=English) or kilometers (Units=Metric) WEIGHT Defaults (to user), typical weight in lbs/kg depending on what setting (UNITS= English or Metric SER NO ,535 Treadmill serial number. LANG English Language in English, Dutch, German, Portuguese, Spanish, Swedish, or Italian. ENTRY Units Tenths Units This variable changes the starting speed in Units or Tenths 3.2

13 Maintenance Mode Maintenance Mode includes all of the items of Manager Mode, plus additional data that is automatically saved to properly troubleshoot in case of a problem. To engage Maintenance Mode: 1. Press and hold the 0, 2 & START keys together. While holding the 0 & START keys down, release the 2 key only. 2. The display will beep and display MAINTENANCE momentarily, then UNITS will be displayed. Once the treadmill is in Maintenance Mode, you may use the following keys: INCLINE KEY: Displays the next or previous parameter. SPEED KEYS: Allows the variable to be changed within the parameter. ENTER KEY: Saves the value if changed in the EPROM (software). Note: ENTER KEY must be pressed, for each value changed. STOP KEY: Exists Manager Mode and restarts the treadmill with a warm start. 0 9 KEYS: Enters new parameter values. If UNITS parameter is displayed, key 5 starts DISPLAY TEST and key 8 starts MOTOR TEST. HEART HEART KEY: When pressed will automatically display manufactures default value. Note: ENTER KEY must be pressed, to save the default values if changed. 3.3

14 Maintenance Mode The following parameters may be changed using the previous keys: Parameters Lowest Value Highest Value Option 1 Option 2 Default Value Meaning UNITS English Metric English English= units of lbs., miles, hours, minutes Metric= units of kg., km, hours, minutes. MN SPD English=0.5 Metric= Minimum speed in MPH or KM/HR MX SPD English=10.0 Metric= Maximum speed in MPH or KM/HR EL OPT ON OFF ON Turns the elevation system ON or OFF. TIME Maximum time in minutes allowed for program, including warm-up/cool-down. OP HRS Total operating hours DIST Total treadmill miles (Units=English) or kilometers (Units=Metric) WEIGHT Defaults (to user), typical weight in lbs/kg depending on what setting (UNITS= English or Metric SER NO Treadmill serial number. LANG English Language in English, Dutch, German, Portuguese, Spanish, Swedish, or Italian. ENTRY Units Tenths Units This variable changes the starting speed in Units or Tenths 3.4

15 Maintenance Mode Parameters Lowest Value Highest Value Option 1 Option 2 Default Value Meaning HRT CON ON OFF OFF OFF= Heart Control disable ON= Heart Control enabled HRT CNT DN POLAR CONTACT BOTH CNT DN POLAR CONTACT BOTH CNT DN CNT DN= Manual countdown heart rate POLAR, CONTACT or BOTH (Polar & Contact) 10 REV = For 110v units = For 220v units 29.1 Inches of running belt travel for 10 flywheel revolutions, measured in inches. 1.8 pulley:30.7 (110v) 2.1 pulley:35.8(220v) CNT/REV = Magnetic RPM Sensor 125 = Optical Sensor 31 Number of counts per RPM Sensor revolution. MN PWM Minimum PWM to obtain minimum speed, automatically done. 1/2 PWM /2 Maximum PWM to obtain 1/2 maximum speed, automatically done. MX PWM Maximum PWM to obtain maximum speed, automatically done. DATE Treadmill manufacturing date. NO STO Number of times the Stop Switch was down or disconnected on power-up since last reset. 3.5

16 Maintenance Mode Parameters Lowest Value Highest Value Option 1 Option 2 Default Value Meaning KEY DN Number of times the Stop Switch was down or disconnected on power-up since last reset. NO RPM Number of times the display did not detect a RMP signal. SP CNG Number of times a sudden change in speed was detected EL STL Number of times an elevation stall was detected. EL RNG Number of counts per RPM Sensor revolution. EL LOST Number of times no elevation was detected. ELZERO Represents the incline number for 0%. EL MAX Represents the incline number for 15%. LSTERR Indicates what display code appeared last. 18 = NO STO 19 = KEYDN 20 = NO RPM 21 = SP CNG 22 = EL STL 23 = EL RNG 24 = EL LOST LSTELV Displays the target elevation prior to the display code. LSTPOT Displays the incline number prior to the display code. 3.6

17 Maintenance Mode Parameters Lowest Value Highest Value Option 1 Option 2 Default Value Meaning LSTRES Displays 1 = Unit was resetting to 0%. 0 = Unit finished resetting to 0% prior to the display code. LSTSSP Displays the speed prior to the display code. LSTPWM Displays the PWM number prior to the display code. LSTMSP Display the actual measured speed prior to the display code. LST TM Displays the elapsed time, in seconds, prior to the display code. LSTDCK Number of miles when the deck was last waxed. After a 2000 mile (or 3000 KM) difference, REWAX BELT will scroll in the display until LST DCK miles are updated. LSTBLT Number of miles when the last belt was replaced. 3.7

18 Motor Test Mode Motor Test Mode allows the treadmill to calibrate both elevation and running belt speed. Verifies RPM Sensor feedback, Drive Motor and MCB response, and verifies Elevation Motor range (count). Also burns in the motor, by way of the controls and displays of the treadmill. ***Caution*** : Do not stand on the running belt while performing these test. Engage Test Mode: 1. Press and hold the 0, 1 & START keys together (or the 0, 2 ). While holding the 0 & START keys down, release the 1 (or 2) key only. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed. 2. Press and release the 8 key. Display will read: if treadmill is at 0%. Alternative mode to enter Motor Test Mode: 1. Turn the power switch on while pressing the 8 key simultaneously on the display A. Elevation Motor Range. B. PWM Duty Cycle. C. RPM Sensor Feedback Once the treadmill is in TEST Mode, you may use the following keys: INCLINE KEY: Adjust voltage to incline motor, inclines the treadmill in increments of 1%. When using the Incline Keys verify the elevation system is responding correctly by the following: As the treadmill elevates up and down verify the corresponding LEDs light up on the MCB. Verify that the Elevation Motor Range (see above A column) is changing in increments of 1% as the treadmill elevates up and down. Caution:Do not elevate treadmill above 15% = 57 (110v units), 80 (220v units) or below 0% = 240 (110 & 220v units) mechanical damage may occur. SPEED KEYS: Adjust the PWM duty cycle and motor speed up and down, respectively, in increments of 0.1 mph (UNITS=English) or 0.1km/hr (UNITS = Metric). When using the Speed Keys verify the speed control system is responding correctly by the the following: As the treadmill begins to increase speed, verify that the display registers RPM feedback (see above C column) in increments of 0.1 mph/km. START KEY: Starts burn-in mode. (continuous operation of running belt and incline using program 8 at maximum speed. Press STOP KEY to stop burn-in. STOP KEY: Exists MOTOR TEST Mode and restarts the treadmill. HEART KEY: Starts automatic calibration of minimum, 1/2 maximum, & maximum speed. 3.8

19 Calibration ***Caution*** : Do not stand on the running belt while performing these test. Automatic Speed Calibration: In this mode minimum and maximum speed is automatically calibrated. Calibration lasts less than 3 minutes; belt will be in motion during this test. Auto-calibration should be done every time MN, MX SPD & UNITS parameters have been changed in either SETTINGS or CONFIGURE Mode. Auto-calibration must be engaged when ever speed controlling components have been upgraded or replaced such as; MCB, Display Board, Drive Motor & RPM Sensor. 1. Press and hold the 0, 1 & START keys together (or the 0, 2 ). While holding the 0 & START keys down, release the 1 (or 2) key. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed. 2. Press and release the 8 key. Display will read: XXX 3.0 if treadmill is at 0% display will read: Press HEART key, display will read: CAL treadmill will go into an automatic speed calibration for less than 3 minutes. Press STOP key to exit Motor Test. NOTE: If Auto-calibration fails to give the correct response refer to Section

20 Display Test Mode Display Test Mode allows you to test the light-emitting diodes (LEDs), 15-segment displays, and the watchdog timer of the Display Control Panel by way of its own controls and displays. It also allows EPROM version to be displayed. To enter Display Test Mode: ***Caution*** : Do not stand on the running belt while performing these test. 1. Press and hold the 0, 1 & START keys together (or the 0, 2 ). While holding the 0 & START keys down, release the 1 (or 2) key. 2. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed. 3. Press and release the 5 key. Observe all the LEDs light up. 4. Pressing any key once will display the EPROM version. Alternative mode to enter Motor Test Mode: 1. Turn the power switch on while pressing the 5 key simultaneously on the display. Observe all the LEDs light up. Once the treadmill is in Display Test Mode, you may use the following keys: INCLINE KEYS: Lights % grade LED s one at a time, also segments of 15-segment screen one at a time. PROGRAM SELECT KEY: Lights the six LEDs bordering the 15-segment display. HEART KEY: Displays HEART HEART on the 15-segment display. START KEY: Displays START START on the 15-segment display. 0 9 KEYS: Lights corresponding LEDs in the Number/Program Select Keys, (except for key 9), alongside the Pre-Designed Program profiles. STOP KEY: Displays WD TEST on the 15-segment display. Activates the watchdog timer, resetting the processor and returning the program back to Start Mode. 3.10

21 Heart Rate Test Heart Rate Test Mode tests the heart rate calculation and display capability of the treadmill if it is equipped with contact rings or Polar wireless heart rate chest strap reception capability. To enter Heart Rate Test Mode: 1. Press and hold the 0, 1 & START keys together (or the 0, 2 ). While holding the 0 & START keys down, release the 1 (or 2) key. 2. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed. 3. Press and release the 5 key. Observe all the LEDs light up. 4. Press the key 3X s, display will read SEEKING HR across the display. 5. Grasp the stainless steel contact rings or place the Polar wireless heart rate chest strap around your chest (treadmill must be equiped with both contact and Polar). 6. In the far right display screen a blinking LED segement will flash then the average heart rate will be displayed. NOTE: If the above Heart Rate Test fails to give the correct reading or response, refer to Section

22 Section 4: Troubleshooting Should the STAR TRAC 4500 Treadmill experience a problem or a display code appear, the following procedures will help determine the precise reason for the problem. Included are flow charts breaking down each individual display code with problem statements and solutions v MCB Layout v MCB Layout 4.5 Calibration Symptoms 4.7 Manual Calibration 4.8 No Display Power 110v 4.9 No Display Power 220v 4.10 Elevation Motor Symptoms 4.12 Elevation Symptoms 4.13 Heart Rate Symptoms 4.16 Polar Symptoms 4.17 Display Cable Symptoms 4.18 Drive Motor Symptoms 4.19 Head / Tail Roller Symptoms 4.20 Drive Belt Symptoms 4.21 Running Belt Symptoms Contents 4.24 Running Deck Symptoms 4.26 Isolating Noise 4.27 Leveling 4.28 Static Symptoms 4.29 Vibration 4.30 Display Codes Chart 4.31 KEY DN Flowchart 4.32 NO STO Flowchart 4.33 No RPM Flowchart 4.37 SP CNG Flowchart 4.41 EL STL Flowchart 4.45 EL RNG Flowchart 4.49 EL LOST Flowchart 4.53 EL NOZ Flowchart 4.0

23 110v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems. ** CAUTION ** AC LED - Indicates that AC power has been applied to the MCB. It does not give indication of voltage level, if this LED is not lit and the tread- mill does not power up, verify the following: 1. The treadmill is plugged into a wall outlet. 2. The ON/OFF switch is turned to the ON position. 3. Verify with a VOLT METER that 110VAC is present at the outlet. Units with step-down transformers need 220VAC. 4. Verify 110v (+/- 10%) AC voltage at AC1 & AC2 wires. After the above have been verified and the AC LED is still OFF, the MCB should be replaced. Several of the following troubleshooting require dealing with live voltage. Have the treadmill turned off and unplugged when checking wire connections. NOTE: The display console may still power up with the AC LED off. +18v LED - Indicates the presence of an acceptable level of voltage to operate the MCB. If this LED is off or dim, the AC voltage level is not acceptable to properly power the MCB. Verify the following: 1. Verify with a VOLT METER that 110VAC is present on on pins AC1 & AC2. After the above step has been verified and the + 18V LED is still OFF, and the display does not power up, replace the MCB. +11v LED - Indicates there is +11 volts supplied to the display board. If this LED is not lit verify the following: 1. The display cable is damaged or pinched, disconnect the display cable and verify if the LED lights up. If LED lights up replace the cable. After the above has been verified and the +11 LED is still OFF, the MCB should be replaced. 4.1

24 110v MCB LED Layout NOTE: Engage Motor Test Mode and manually push on the running belt to verify RPM feedback. MOTOR LED - Indicates the presence of acceptable voltage to the motor. If this LED is not lit one of the following conditions exists: 1. Verify AC voltage is being applied. 2. Verify that MTR1/MTR2 wires are connected to the MCB. (This should be done with the treadmill unplugged and turned off) After the above have been verified and the MOTOR LED is still OFF, the MCB should be replaced. PWM LED - Indicates that there is a valid control command from the display to the MCB (this LED flashes only when the treadmill is operating) If this LED is not lit verify the following: 1. Verify if the display cable is connected. 2. Verify if the display cable is damaged or pinched. (see page 4.17 in this section for Display Cable symptoms) After the above have been verified and the PWM LED is still OFF, the MCB should be replaced. NOTE: If the current limit is reached, the MCB will shut the treadmill down and the I-LIMIT LED will remain on until it resets. I-LIMIT LED - Indicates that an excessiveload is being placed on the motor. Amp readings of 26 or higher will cause the LED to light. If this LED is lit one of the following conditions exists: 1. Running belt is worn. 2. Belt and deck require lubrication. 3. Drive motor drawing over the 26 amp peak. After the above has been verified and the I-LIMIT LED is still ON, the MCB should be replaced. UP LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following: 1. Display cable for possible pinch or tear (see page 4.17 in this section for Display Cable symptoms) 2. Replace MCB. DOWN LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following: 1. Display cable for possible pinch or tear (see page 4.17 in this section for Display Cable symptoms) 2. Replace MCB. 4.2

25 220v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems. ** CAUTION ** AC PWR - Indicates that AC power has been applied to the MCB. It does Several of the following troubleshooting steps require dealing with live voltage. Have the treadmill turned off and unplugged when checking wire connections. not give indication of voltage level, if this LED is not lit and the treadmill does not power up, verify the following: 1. The treadmill is plugged into a wall outlet. 2. The ON/OFF switch is turned to the on position. 3. Verify with a VOLT METER that 110VAC is present at the outlet. Units with step-down transformers need 220VAC. 4. Verify 220v (+/- 10%) AC voltage at AC1 & AC2 wires. After the above have been verified and the AC LED is still OFF, the MCB should be replaced, if the treadmill is not operating. NOTE: The display console may still power up with the AC PWR LED off. DISPLAY PWR- Indicates there is +11 volts supplied to the display board. If this LED is not lit verify the following: 1. The display cable is damaged or pinched, disconnect the display cable and verify if the DISPLAY PWR LED lights up. If the LED lights up replace the cable. After the above has been verified and the DISPLAY PWR LED is still OFF, the MCB should be replaced. 4.3

26 220v MCB LED Layout NOTE: Engage Motor Test Mode and manually push on the running belt to verify RPM feedback. RPM SENSOR - Indicates input signal from the RPM Sensor to the MCB. If this LED is not flashing during operation, verify the following 1. RPM sensor disconnected from connector J3 at the MCB. 2. RPM sesnor gap misaligned. 3. RPM sensor faulty After the above have been verified and the RPM LED is still OFF, the MCB should be replaced. MOTOR CONTROL - Indicates that there is a valid control command from the display to the MCB. If this LED is not lit verify the following: 1. Verify if the display cable is connected. 2. Verify if the display cable is damaged or pinched. After the above have been verified and the MOTOR CONTROL LED is still OFF, the MCB should be replaced. UP LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following: 1. Display cable for possible pinch or tear ( see page 4.17 in this section for Display Cable symptoms). 2. Replace MCB. DOWN LED - Indicates that the incline is being commanded down. If this LED is not lit and the elevation motor will not respond, verify the following: 1. Display cable for possible pinch or tear ( see page 4.17 in this section for Display Cable symptoms). 2. Replace MCB. 4.4

27 Calibration Troubleshooting The following steps help troubleshoot in case Auto-Calibration procedures fail to give the correct reading or response. Symptom: Auto-Calibration fluctuates. Diagram #1 1. Verify line voltage for sufficient voltage supply. If wall voltage is less than 10% than what is required, this will cause speed fluctuation. 2. Verify unit is on a dedicated circuit breaker. Treadmills sharing the same circuit line will cause intermittent problems and variation in speed. 3. Verify the following parameters are set correctly in the Configuration Mode: (Configuration Mode details in Section 3) CNT/RV : 31 = Magnetic/Cherry RPM Sensors 10 REV: 29.1 for 1.7 dia. motor pulley (110v) 10 REV: 35.8 for 2.1 dia. motor pulley (220v) NOTE: If not sure what your 10 REV settings should be, manually measure your drive motor pulley diameter. Above measurements are done in inches. 4. Verify RPM Sensor alignment. Hall Effect/Cherry RPM Sensor is being used, verify the gap is no more than 1/8 inch. NOTE: See Diagram # Adjust IR COMP potentiometer. NOTE: See Diagram #2, adjustment. REPLACE: MCB if symptom continues. 4.5

28 Calibration Troubleshooting Symptom: Will not Calibrate to MAX speed. Diagram #1 1. Verify line voltage for sufficient voltage supply. If wall voltage is less than 10% than what is required, this will cause speed fluctuation. 2. Verify unit is on a dedicated circuit breaker. Treadmills sharing the same circuit line will cause intermittent problems and variation in speed. 3. Verify the following parameters are set correctly in the Configuration Mode. (Configuration Mode details in Section 3) MN SPD: 0.5 MPH or 1.0 KM/PH MX SPD: 10.0 MPH (110v) or 20.0 KM/PH (220v) CNT/RV : 31 = Magnetic/Cherry RPM Sensors 10 REV: 29.1 for 1.7 dia. motor pulley (110v) 10 REV: 35.8 for 2.1 dia. motor pulley (220v) NOTE: To reach 20.0 KM/PH on 220v units, drive motor pulley must be 2.1. If not sure what your 10 REV settings should be, manually measure the drive motor pulley diameter. Diagram #2 4. Verify RPM Sensor alignment. Hall Effect/Cherry RPM Sensor is being used, verify the gap is approximately 3 business cards or 1 credit card. If adjustment is necessary loosen the flywheel to re-position. NOTE: See Diagram #1. REPLACE: RPM Sensor if RPM reading is sensitive or feedback appears erratic. 5. Adjust the MAX SPEED potentiometer. NOTE: See Diagram #2. (220v units only) GO TO: Section 3.7 Manual Calibration if problem continues. 4.6

29 Manual Calibration The following procedure allows the treadmill to manually calibrate Minimum and Maximum speeds, only in the case Auto-Calibration is not functioning correctly. Symptom: Will not calibrate to MN or MX speed, in the Auto-Calibration Mode. **CAUTION** 1. Engage TEST MODE. Press and hold the 0, 1 & START keys together Do not stand on (or the 0, 2 ). While holding the 0 & START keys down, release the 1 the running belt (or 2) key. The display will beep and display SETTINGS (or CONFIGURE) while perform- momentarily, then UNITS will be displayed. ing these steps. 2. Press and release the 8 key. Display will read: XXX 3.0 XXX is a variable NOTE: Alter- number depending on the elevation position the treadmill is at. 3 indicates Speed native mode to Command, 0 indicates RPM. If the treadmill is at 0% the display will read: enter Motor Test Mode; turn 3. Press the + key (speed) to the desired MN SPD,1/2 MX, and MX SPD. Write the power down the corresponding Speed Command number displayed for each desired switch ON setting. while pressing the 8 key sim- 4. Press the STOP key. Engage Configuration/Settings Mode as described in ultaneously on STEP 1. the display. 5. Using the UP ELEVATION key go to MN PWM parameter and enter the new NOTE: The MN MN SPD Speed Command number by using the + or - keys, then press the SPD should not START (enter) key to save the new setting. Do this for the 1/2 MX and MX SPD. exceed.5 MPH or 1KPH. The 6. Press the STOP key to exit. 1/2 MX SPD should be exactly half of the desired MX SPD. The MX MX SPD must not exceed 10 MPH or 20 KPH (220 units). NOTE:Speed Command 255 is the maximum the treadmill will reach. 4.7

30 No Display Power The following steps help troubleshoot in case the display board fails to power up, during or before regular operation. 110v UNIT Diagram A Diagram B 1. Lift and suspend the motor shroud. **CAUTION** The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to are performed with the MCB, does not indicate voltage level. If this LED is lit go to step 3. the treadmill ON. If LED is not lit verify the following: (see diagram A) The treadmill is plugged into the wall. The ON/OFF Switch is turned to the ON position. Verify wire connection AC1/AC2 on the MCB. Verify the ON/OFF Switch Breaker wires are connected. Verify 110v (+/- 10%) AC voltage at AC1/AC2. if the voltage is 0 or less than 90v, check wall voltage, verify unit is on a dedicated line. If wall voltage is correct, verify linecord continuity. (see diagram B) REPLACE: MCB if all the above check OK. 3. Verify if LED +18 is lit. LED +18 indicates the presence of an acceptable level of voltage for MCB operation. REPLACE: MCB if +18 is not lit. 4. Verify if LED + 11 is lit. LED +11 indicates 11v are being applied to power the display board. If the LED is lit go to step 5. REPLACE: MCB if +11 is not lit. 5. Verify display cable connection. Verify display cable for possible pinch or tear mark. REPLACE: Display board if display cable checks OK. 4.8

31 No Display Power The following steps help troubleshoot in case the display board fails to power up, during or before regular operation. 220v UNIT Diagram A Diagram B 1. Lift and suspend the motor shroud. **CAUTION** The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to are performed with the MCB, does not indicate voltage level. If this LED is lit go to step 3. with treadmill ON. If LED is not lit verify the following: (see diagram A) The treadmill is plugged into the wall. The ON/OFF Switch is turned to the ON position. Verify wire connection AC1/AC2 on the MCB. Verify the ON/OFF Switch Breaker wires are connected. Verify 220v (+/- 10%) AC voltage at AC1/AC2. if the voltage is 0 or less than 200v, check wall voltage, verify unit is on a dedicated line. If wall voltage is correct, verify linecord continuity. (see diagram B) REPLACE: MCB if all the above check OK. 3. Verify if LED DISPLAY POWER is lit. This LED indicates 11v are being applied to power the display board. If the LED is lit go to step 4. REPLACE: MCB if DISPLAY POWER LED is not lit. 4. Verify if LED MOTOR CONTROL is lit. This LED indicates there is a valid control command from the display to the MCB. Verify the following if LED is off: Verify display cable connection. Verify display cable for possible pinch or tear mark. REPLACE: Display board if display cable checks OK. 4.9

32 Elevation Motor The following procedure explains the elevation system Thermal Protection and limitations. NOTE: Activation of the thermal protection breaker does not cause damage to the elevation actuator or other treadmill components. Symptom: Elevation system shuts-off when used consistently. 1. The Star Trac Model 4500 elevation system actuator is protected from overheating by a thermal protection circuit. In the event that the thermal protection breaker is activated, the treadmill s elevation system is temporarily disabled, and an EL STL display codes is displayed. A simple resetting of the treadmill restores full operation once the elevation actuator has been allowed to cool for a few minutes. 2. The pre-defined workout programs 1 through 8 as well as other typical workout regimens include elevation changes that easily fall within the operating limits of the Model 4500 s elevation system actuator. The following information serves as a guide for users that may wish to set a custom program that requires frequent and/or large changes in incline. Incline changes greater than 5 percent should not be programmed for intervals less than 1 minute. Full range incline changes (from 0 percent to 15 percent, or viceversa) should not be programmed for intervals less than 3 minutes. 4.10

33 Elevation Motor The following procedure verifies elevation motor potentiometer response. ** CAUTION ** Do not stand on the running belt while performing these steps. NOTE: Several of the following steps require dealing with live voltage. Have the treadmill turned off and unplugged when checking wire connections. NOTE: The potentiometer values can be read in Motor Test Mode, 240 = 0%, 57 = 15% for 110v units or 80= 15% for 220v units. NOTE: The values in diagram A were taken from a properly functioning elevation system. You may expect slight variation from machine to machine. If the values are 0, check display cable for possible short see page 4.17 Display Cable Symptoms. If values are erraticly different replace the Elevation Motor. Symptoms: Elevation motor hesitates during operation. No elevation count reading in Test Mode. 1. The elevation motor potentiometer may have failed or register incorrect values causing the motor to hesitate while operating. The chart below (see diagram A) is a guide for the correct elevation readings on the TR Using a Volt Meter verify the following values from the elevation motor at certain elevation grades (see the chart for elevation grades). The voltage readings may vary by +/-.05 volts. The ohms may vary by +/-.01 k ohms. See diagram B for meter reference. Diagram A. % Grade Incline number in Motor Test Mode DC Voltage across Blue and Orange wire on the Elev. motor connector Ohm reading between the Blue and Orange (elev. motor unplugged) DC Voltage on Pin 4 of the display electronics k k k k k k k k k k k k k k k k

34 Elevation Troubleshooting 220v treadmill Incline Range Adjustment for Free-wheeling symptom. ** CAUTION ** Do not stand on the running belt while performing these steps. Symptom: Treadmill free-wheels at high elevation, causing the running belt to slowly accelerates beyond the selected speed. 1. This symptom may be easily fixed by changing certain values in the Configure Mode. Engage Manager/Maintenance Mode by holding down the 0, 1 and Start keys at the same time, and then release the 1 key only. 2. Press the elevation key until the display window reads EL MAX 57. Change the 57 to 80 by pressing the + key. 3. Press the START key and the display window will show UPDATING. This will save the 80 in the parameter. 4. Press the STOP key to exit the Manager or Maintenance Mode. Procedure completed. Symptom: Elevation Motor overheats and blows the MCB fuse. NOTE:These ranges were chosen to optimize the output voltage to the elevation motor within an acceptable operating range, while still using the present manufacturing tolerances of the transformer manufacturer. 1. The elevation motor on the 4500 series treadmill uses 115 VAC. On 230 volt treadmills, there is an autotransformer which will lower the voltage to operate the elevation system. 2. Line voltage may vary from location to location. Some locations have line voltages as low as 195 VAC or as high as 250 VAC. The autotransformer has been manufactured with two taps to accommodate these variations in voltage. The two taps are: 190 to 210 VAC line voltage 210 to 250 VAC line voltage 4.12

35 Speed Troubleshooting Note: This symptom may be easily fixed by verifying certain values in the Configure Mode. Symptom: Treadmill appears/feels faster/slower than other STAR TRAC treadmills. 1. Engage Maintenance Mode by holding down the 0, 2 and Start keys at the same time, and then release the 1 key only. Display will read MAINTENANCE momentarily then display UNITS. Note: For each value changed the ENTER key must be pressed to be saved.. 2. Using the elevation key to go through the parameteres, verify the following parameterts have the correct values. 110V / 220V Units English 220v Units Metric UNITS ENGLISH METRIC MN SPD MX SPD ENTRY UNITS/TENTHS UNITS/TENTHS 10 REV CNT/REV If any values have been changed or set back to default settings, re-engage Auto-Calibration and re-calibrate. 4.13

36 Speed Troubleshooting Symptom: Treadmill will not reach maximum speed. Note: This symptom may be easily fixed by verifying certain values in the Configure Mode. Note: For each value changed the ENTER key must be pressed to be saved. Note: All 110v units are designed to reach a maximum speed of 10.0 MPH. 220v units set in metric will reach a maximum 20.0 KM/PH. Note: Wall voltage is very critical when dealing with maximum speed. Voltages under 100v for 110v units will cause speed variation, voltages under 200v for 220v units will cause the same problem. Note: Each unit must be on its own dedicated circuit, very main wall breaker. 1. Engage Maintenance Mode by holding down the 0, 2 and Start keys at the same time, and then release the 1 key only. Display will read MAINTENANCE momentarily then display UNITS. 2. Using the elevation key to go through the parameters, verify the following parameters have the correct values. 110V / 220V Units English 220v Units Metric UNITS ENGLISH METRIC MN SPD MX SPD ENTRY UNITS/TENTHS UNITS/TENTHS 10 REV CNT/REV If any values have been changed or set back to default settings, re-engage Auto-Calibration and re-calibrate. IF the problem continues verify the following. 1. Wall voltage. (+/- 10%) 2. Dedicated Circuit Breaker. 3. Adjust MAX SPEED potentiometer (220v units). See Diagram below: 4.14

37 Speed Troubleshooting Symptom: Treadmill jerks or hesitates during operation. ** CAUTION ** Running belt will be moving at high speed during Step 1 & 3. ** CAUTION ** When checking motor brushes have the treadmill turned off and unplugged. Note: Brushes should show a smooth pattern of wear, cracks or unusual wear will cause motor to jerk, replace if brushes if neded. 1. Verify the running belt / drive belt are not loose or slipping. Accelerate the running belt to 3.0 (5.0 kph). Stand on the side of the treadmill, while grasping the handrails firmly, place one foot on the running belt with a very sharp impact. Running belt should not stop, instead slip for a split second forcing your foot back. Drive belt should never stop rotating over the headroller during this procedure. If running belt or drive belt appears loose, see page 4.26 in this section. 2. Verify motor brushes are making contact and are seated correctly. Remove the motor brush cover, check brushes are seated correctly by removing the brush clip and verify contact. See diagram A for removal instructions. Cleaning the motor armature with a commutator stone is highly recommended to remove any possible carbon dust build up, causing the the brushes to skip over resulting in a brief motor hesitation. 3. Adjust the IRCOMP potentiometer, located on the MCB, see diagram B. Bring the treadmill to its minimum speed. Stand on the running belt, if the belt feels jerky / hesitates adjust the IRCOMP potentiometer until running belts feels smooth. Symptom: Treadmill hesitates during initial speed start-up. 1. Manually calibrate the minimum PWM as described in page 4.7 in this section. 4.15

38 Heart Rate Troubleshooting ** CAUTION ** Do not stand on the running belt while performing these steps. Before any troubleshooting is performed, verify that the heart rate grips are being used and maintained properly. Symptom: Intermittent or erratic heart rate reading. 1. User failing to grip all four rings completely with both left and right hands 2. An excessively tight grip on the rings can cause erratic readings. The probability of erratic readings can be therefore lessened by: ---- reduced upper torso movement ---- a proper grasp on the grips ---- clean hands ---- clean grips 3. Excessive foreign matter (dirt) on the hands can generate electrical interference which will cause erratic readings. 4. Clean and wipe heart rate grips after each use, for optimum results. 4.16

39 Symptom: No Heart Rate reading. 1. Engage HEART RATE TEST. Turn the power switch on while pressing key 5 simultaneously on the display. All the display LEDs will light up when engaged. Press the HEART key once, EPROM version will be displayed. HEART key twice, displays Heart/ Seeking HR. Grip heart rate handles, The negative (-) symbol will begin to flash indicating heart rate system is being registered. Do not squeeze excessively to avoid excessive muscle contraction (faulse readings). If no reading is displayed go to STEP 2. Heart Rate Troubleshooting Diagram 1 2. Verify Contact Heart Rate settings. Engage MANAGER MODE, Hold the 0, 1, and START keys together and release the 1 key only. Display will read MANAGER MODE momentarily, then UNITS will be displayed. Scroll through the parameters using the elevation UP key until display reads: CONTCT= contact heart rate. BOTH = both contact and polar can be used (if software available). Press the + or - key to change, START key to save. Diagram 2 3. Verify Heart Rate receiver connection. Remove the display board, verify wire connections. NOTE: See diagram #1 Display removal. NOTE: See diagram #2 Wire connection. Connection is wrong or loose, reconnect and repeat step Verify Heart Rate grip cables. NOTE: See diagram #3. If connections are wrong or loose, reconnect and repeat step 1. Diagram

40 Heart Rate Troubleshooting 5. Connect Heart Rate Board straight to the display input. By-pass the Combiner Board, insert the heart rate wires straight to the display. See Diagram #3 & 3a. After connection has been repeat step 1. REPLACE: Combiner Board if Heart Rate registers. If no Heart Rate is registered go to step 6. NOTE: Step 5 can only be performed if the software includes both Polar and Contact. Diagram 4 Diagram 5 6. Check continuity/resistance between Heart Rate grip rings and input wires. Disconnect both heart rate grip inputs (red & black wires) from back of display. Using a Multi-meter check continuity between the heart rate rings and its corresponding output wires. Red wire = outside rings. Black wires = inside rings. NOTE: See Diagram #4. REPLACE: Heart Rate grip(s) if reading is greater than 1.0Ω Diagram 6 7. Check continuity/resistance of each hand rate grip. Using a Multi-meter check continuity between the two rings on the same grip. Black meter probe to inside ring and red meter probe to outside ring. NOTE: See diagram #5. REPLACE: Heart Rate grip(s) if reading is lower than 3 MΩ. Diagram 7 8. Check continuity/resistance between the two hand rate grips. Measure the resistance between the two outside rings. NOTE: See diagram #6. REPLACE: Heart Rate grip(s) if reading is less than 18.0Ω 4.18

41 Polar Heart Troubleshooting If the display is having difficulty picking up polar heart rate readings, verify proper usage. ** CAUTION ** Do not stand on the running belt while performing these step. NOTE: Secure the chest strap transmitter as high under the pectoral muscle (breast) as is comfortable and allow normal breathing. Symptom: Intermittent or erratic polar heart reading. 1. The maximum distance for polar heart rate to receive a signal is 3 feet. 2. Verify chest strap is correctly positioned. Chest strap electrodes must be properly positioned and wet. See below diagrams. NOTE: Wet the electrodes (the two grooved rectangular areas) thoroughly with water. NOTE: Verify heart rate response without operating the running belt. Straddling the treadmill press the HEART key If heart rate is not picked up engage Heart Rate Test, refer section Connect Polar Board straight to the display input. By-pass the Combiner Board, insert the heart rate wires straight to the display. See Diagram 1 # 1a REPLACE: Polar Board if Heart Rate registers. If no Heart Rate is registered go to. 4.19

42 Display Cable The following symptoms indicates a faulty or pinched display cable. Symptom: No display power related. **CAUTION** 1. No display power, treadmill elevation bottoms out during start-up. Do not stand on 2. No display power, MCB LED +11 remains lit on 110v units. MCB LED Display the running belt remains lit on 220v units. while performing these steps. Intermittent or no elevation. NOTE: Alternative mode to enter Motor Test Mode; turn the power switch ON while pressing the 8 key simultaneously on the display. 1. In Test Mode only up direction works, MCB LED UP remains lit. 2. In Test Mode no elevation count (elevation motor pot), will elevate both directions reads EL LOST across display in regular operation mode. 3. In Test Mode no elevation response, reads EL STL across display in regular operation mode. 4. In Test Mode elevation count registers slow to actual elevation response. 5. Treadmill elevation without command in regular operation mode. 6. Elevation motor hesitates in between elevation percents, MCB LEDs UP & Down toggle back and forth. 7. Elevation intermittently responds, registers different elevation display codes in regular operation mode. Intermittent or no speed reading 1. In Test Mode belt movement, but no RPM reading. MCB LED RPM remains of on 220v units. registers NO RPM code across display in regular operation mode. 2. In Test Mode or regular operation mode, RPM reading intermittently flashes. 3. In Test Mode or regular operation mode, RPM speed fluctuates. 4. In Test Mode MCB LED PWM (110v units) or MOTOR CONTROL (220v units) remains off and no RPM reading is registered. 4.20

43 **CAUTION** Drive Motor The following symptoms indicates a faulty drive motor. Symptom: Tripping the ON/OFF switch breaker. 1. Disconnect the drive motor belt. Do not stand on 2. Run the drive motor for ten minutes at a high speed (6 MPH/ 10 KPH). If the the running belt ON/OFF switch trips, verify if the MCB LED I-LIMIT lights up (110v units), this while perform- would indicate Drive Motor pulling higher amps than desired. ing these steps. Drive Motor making noise. NOTE: If the ON/OFF swith 1. Disconnect the drive motor belt. trips only with a 2. Isolate the noise. Bellow is a list of discriptions related to motor noise: load, running ----Knocking; Noise described for bearing failure or motor magnet. belt may be ----Grinding ; Noise describing bearings, motor brush wear. worned. ----Squeaking; Motor brushes installed incorrectly, flywheel loose, motor bearings. ----Howling; Usually described when motor increases to higher speeds. 4.21

44 Head / Tail Roller You may need to replace the head or tail roller if the following symptoms are observed. Symptom: Thumping, knocking noise as the running belt goes over the roller. Verify the following: Delron end caps are loosening. Bearings are grinding or knocking. Lagging (coating) is loose. Thumping sounds (may also indicate a possible wax build up). The running deck surface is coated with a special wax. During breaking period (first hours of operation), some wax may form on the tail roller causing a loud thumping noise. In worse cases, this may cause mistracking. If the thumping noise continues, remove the wax buildup. With the following procedure: Note: Do not remove all the was as it is required to lubricate both the running belt and deck. 1. Loosen or remove the tail roller by backing of the Allen screws. Use a ¼ Allen wrench. 2. Remove the largest buildup of wax deposits from the tail roller. Use a plastic scraper, credit card or piece of wood. Never scrap with a sharp metal object. 4.22

45 Drive Belt Troubleshooting The drive belt tension may require tightening if a slipping problem occurs on the drive pulley. Symptom: Running belt slips when running or walking. 1. Loosen the four motor mount kep nuts and washer using a 5/16 wrench. 2. Adjust the drive belt tension by turning the motor mount adjustment (socket head cap) screw. See diagram below. Tension should be no more than 90 lbs. If too tight, turn the belt tension screw counter-clockwise. If too loose, turn the belt tension screw clockwise. 3. Simultaneously tighten the belt tension lock nut while holding the belt tension screw with a 5/16 wrench. 4. Simultaneously tighten the right, rear, motor mount nut, then tighten the remaining bolts. 5. Verify if the belt is tensioned properly. 4.23

46 Running Belt Troubleshooting Note: For optimal To prevent belt problems from occurring, verify the running belt is properly performance during the adjusted and working smoothly by performing the following steps: lifetime of the treadmill, running belt adjust- 1. Feel the underside center of the running belt, for glaze. Glaze is ments may become described as a smooth glass texture, the correct feeling should be a necessary. All adjust- rough texture such as found on the undersides of the belt. ments are performed by adjusting the tail roller Allen screws If glazed, replace the running belt. Contact your local retailer or act with a 1/4 Allen STAR TRAC Product Support Department at or through wrench. our web site at 2. Activate the treadmill. Stand at the back of the treadmill and visually inspect the running belt. The running belt should move smoothly, without drifting to far to the left or right. This will cause fraying or damage to the running belt. For proper tension and tracking, refer to Running Belt Tension and Running Belt Tracking in this section. If you observe the following symptoms, running belt needs to be replaced 1. On/off switch tripping to the off position after treadmill is used for short period of time. 2. Running belt continues to slip after tightening. (Provided the drive belt has been checked for proper tension) 3. Edges of the running belt are frayed. 4. Running belt seam is coming apart. 5. Running belt beginning to fold in the middle. 4.24

47 Running Belt Tracking Note: The running belt If the running belt is not centered on the tailroller and is either to far left or may mis-track due to right, adjust tracking using the following steps:: the style of the walker or runner. 1. Turn treadmill on. Increase speed to 3.0 mph (5.0 kph). Note: The running belt 2. Adjust tracking by adjusting the tailroller Allen screws located at the back will track to the side sides of the tail roller with a 1/4 Allen wrench in 1/4 turn increments. less tensioned. (See below diagram) If the running belt is tracking to the left, adjust the running belt to track to the right. Tighten the left tailroller Allen screw by turning clockwise or loosen the right tail roller bolt by turning counter-clockwise. If your running belt is tracking to the right, then adjust the running belt to track to the left. Tighten the right tail roller Allen screw by turning clockwise or loosen the left tail roller bolt by turning counter-clockwise. 3. After running belt appears to be tracking properly, increase speed to 10 mph (16 kph) and verify belt stays centered. Note:To ensure proper tracking, the treadmill leveling feet must be adjusted to conform to the floor surface. For proper procedure see Feet Leveling in this section. 4. Verify correct running belt tension as outlined in the Running Belt Tension procedure in this section. 4.25

48 Running Belt Tension Note: Prior to making The running belt tension may need to be adjusted over time to keep the any adjustments to the the belt from slipping with each jogging step or at high speeds. Use the running belt tension, following procedure for testing belt tension. verify the drive motor belt is properly 1. Accelerate the running belt to 3.0 mph (5.0 kph). tensioned. 2. Stand on the side of the treadmill. Grasping the handrails firmly, place one foot on the running belt with a very sharp impact. The running belt should not come to a complete stop. The running belt should slip for a split second, then forcing your foot back. If the running belt does not stop with impact, the running belt may be to tight and cause the belt and other components to premature fail. Loosening the tail roller Allen screws a 1/4 of a turn counter-clockwise and re-checking will be necessary. If the running belt stops and noticeable slippage occurs, check the location of the slippage. It can be slipping due to the drive belt slipping over the drive motor pulley and head roller or from the running belt slipping over the rollers If the slippage is caused from the drive belt slipping over the drive motor pulley, loosen the motor mount bolts located at the mount of the drive motor and tighten the adjustment bolt. For detail more details refer to Drive Belt Tension procedure in this section. --- If the slippage is caused by the running belt slipping over the rollers, tighten the running belt. Note: If you do not 3. Tighten the left and right tail roller Allen screws clockwise in equal 1/4 tighten Allen screws in increments. Repeat Step Two until running belt is tensioned properly. equal increments, you will mis-track the running belt. Verify correct belt tracking procedure. The running belt has been tightened too much and may require loosening, if: Note: Do not over 1. The edges of the running belt curls down or up, causing the middle of the tighten the running belt. belt to bubble up. Over tightening will cause premature 2. Running belt creaks as it goes over the rollers. failure. Note: If the running 3. Treadmill trips the circuit breaker (on/off switch) after tensioning. belt creaks in spite of being loosened, apply dry lubricant, such as TFE Teflon or powered wax to the deck. 4.26

49 Running Deck The following procedure will help determine and properly adjust the deck bumpers. Symptom: Running deck squeaks when running. 1. When properly located, the side bumpers (two on each side) bear against the delrin rods in the frame rails. The rear bumpers bear against the steel posts at the end of the frame rails. If the bumpers are not located so they bear against the rods as described, the running deck may shift to one side or the other during use. This allows the rear edge of the deck to rub against the steel post. This causes a high-pitched squeak as the user runs on the treadmill. 2. To determine if a deck has the bumpers properly located, look under the end cap/finger guard to see if the bumpers on the end of the deck bear against the steel posts. A problem definitely exists if the bumpers are to one sode of the steel posts and the edge of the deck is bearing against the posts. 3. Remove the screws securing each of the four delrin rods and pull them out. Look through the hole in the frame to see if the running deck bumper is adjacent to the hold, such that it would bear against the delrin rod if it was reinstalled in the hole. If all bumpers are properly located, replace the delrin rods and examine the treadmill further for the other causes of squeaks. If one or more bumpers is misalign, follow the procedure given below. 4.27

50 Running Deck Symptom: Running deck squeaks when running (continued). Correcting the problem: 1. Position the deck with the rear bumpers properly aligned with the steel posts. With a pencil, make a mark on the deck adjacent to each of the four delrin rods( as seen from the top of the side rails). 2. Reach under the running deck, shift the deck as far as possible to tone side. On the side that now has the edge of the deck exposed from under the frame, pull the rear edge of the deck upward until it is just above the frame rail. Use a screwdriver or putty knife to hold the deck above the frame. Using another screwdriver, raise and hold the front of the deck. 3. Remove the bumper(s) that are not aligned with the pencil marks by carefully prying them away from the deck with a screwdriver, knife or putty knife. 4. Position the bumpers (removed in the previous step) so they are adjacent to the pencil mark(s), and drive them into the edge of the deck using a hammer. 5. Once the bumpers on the side have been installed in the proper locations, remove the screwdrivers used to hold the deck above the frame. 6. Repeat process on opposite side of the treadmill. 7. After the bumpers have been properly installed on both sides of the running deck, position the deck properly, and verify that all bumpers have adjacent o the holes. Reinstall the delrin rods. 8. Test the treadmill thoroughly. The squeak should be gone. 4.28

51 Isolating Noise NOTE: Verify that the treadmill is level before isolating any specific component NOTE: Ensure all assembly screws are tight: 1. Handrails. 2. Display board. 3. Motor shroud. NOTE: When doing the stethoscope method, be careful of body placement. Ensure all loose items (hair, clothing, jewelry etc) are secure and away from moving parts. Sounds travel throughout the treadmill making it difficult to isolate the cause of a sound. The following procedure will help determine where a noise may be coming from. Isolate the noise. 1. If the noise seems to be coming from two different parts (drive motor or roller etc.), isolate the noise by disconnecting the drive belt. Then run the drive motor by itself. If the noise goes away, manually push the running belt to see if the noise returns. If it does, then it is coming from the rollers. 2. Isolate the rollers. Adjust the tension on the tail roller screws until the running belt is loose. Spin each roller by itself to determine where the noise is coming from. The Stethoscope Method 1. Using a long screwdriver as a stethoscope put the handle of the screwdriver to your ear. Place the opposite end of to the area where you are listening. This will help locate where a specific noise is coming from. Symptoms: Rumbling Wax buildup on the rollers. Head / tail roller bearings. Adjustable feet / leveling. Floor condition; thick carpet or wood floors. Elevation screws dry. Elevation motor stripped. Squeaking Deck rubbing against the frame. Adjustable feet / leveling. Head roller and drive motor pulleys not aligned. Drive belt tensioning. Running belt tensioning. Drive motor brushes. Knocking Drive motor bearings. Head / tail roller bearings. Running belt hitting the back or front of the frame. Missing or worn deck cushions. Grinding Drive motor bearings. Head / tail roller bearings. Motor brushes worn. 4.29

52 Leveling To ensure proper tracking of the running belt, treadmill leveling should be verified. NOTE: If a leveling foot does not make contact with the floor or if it lifts upwards as weight is applied to one corner of the deck, this will cause the running belt to mis-track. Symptoms: Running belt travels to one side. Treadmill vibrates. Leveling feet must be adjusted to conform to the floor surface. After the treadmill has been leveled, tracking of the belt must be tested and adjustments made as necessary. This two step procedure is particularly important for treadmill installed in a residence, where floors are commonly uneven. When a treadmill is installed on carpet, a repeat adjustment may be required after the carpet and padding have been compressed by the treadmill feet. 1. Place the treadmill in the exact location where it is to be used. 2. Check the leveling feet at each corner of the treadmill to ensure that they make contact with the floor surface. It may be helpful to have one person bear their weight at one corner of the running belt, then move to another corner, etc., while another person notes whether one or more corners lift from the floor as weight is applied Using a 9/16 inch open end wrench, loosen the lock number (see diagram) Adjust leveler height by turning the leveler base. The wrench may be used on the lower nut for this purpose Tighten the lock nut. 4.30

53 Vibration A treadmill vibrates during use if the floor or leveling feet are uneven or when assembly bolts are loose. Symptom: Unit vibrates while running. NOTE: For complete leveling procedure, see the following page. 1. Verify the treadmill is on an even, uncarpeted floor. If no, move the treadmill to an even floor. If floor is carpeted, place the treadmill on a rubber mat. 2. Verify that the Leveling feet are adjusted correctly. 3. Verify the following assemblies. Handrails Slick deck Display board Motor mount Flywheel NOTE: When checking motor brushes, the treadmill must be turned off and unplugged. 4. Remove the drive belt and isolate the motor. If the drive motor vibrates, check motor mount bolts. Verify that the motor brushes aren t cracked. 4.31

54 Static Shock **CAUTION** When checking motor brushes, always turn the treadmill off and unplug. The treadmill may cause a slight shock from the display panel or handrails, due to a faulty ground wire or a worn running belt and deck. Symptom: Slight shock from handrails or when using the display panel. 1. Check the line cord and plug prongs for signs of damage. Verify no prongs are broken, loose or missing. 2. Check the green ground wires attached to the frame for the following: Motor Line cord 3. Check running belt condition. Check for glazing. Replace the running belt if glazed. Wax slick deck. 4. Check drive motor conditions Verify motor brush wear. 4.32

55 ** CAUTION ** Do not stand on the running belt, while performing these steps. NOTE: Treadmill should be turned off and unplugged from the wall when looking under the motor shroud. NOTE: Contact STAR TRAC Product Support Department at or through our web site at Please have your serial number and display code available. Display Codes Chart STAR TRAC recommends that you refer your questions about your STAR TRAC 4000 TREADMILL operation and suspected malfunctions to STAR TRAC s PRODUCT SUPPORT DEPARTMENT. However, you may wish to investigate display codes that appear on the display. You may do so by reviewing the below chart or follow the step-by-step flowcharts for the corresponding display code. Display Codes/Symptoms KEY DN This code generally occurs when a key other than 5 or 8 is held pressed while turning the treadmill ON using the on/off switch. It may also happen if a key becomes stuck. NO STO This code generally occurs when the Stop Switch is not connected tightly to the electronic board of the Display. It may also happen if the circuitry associated with the switch develops a fault. NO RPM / SP CNG These codes generally occur when the RPM (speed sensor) is disconnected, faulty, or misaligned. They may also happen if the RPM Sensor cable is damaged. Motor Control Board (MCB) is misadjusted, miscalibrated. or faulty. Pinched or faulty Display Cable. Drive Motor arcing or faulty. EL STL, EL RNG, EL LOST and EL NOZ These display codes generally occur when the elevation (incline) potentiometer is faulty or out of limits. Elevation motor disconnected or receiving low power. May also happen if the MCB is miscalibrated or faulty. Display Cable pinched or faulty. Elevation Belt damaged or binding. 4.33

56 Code: KEY DN Flowchart Definition: "KEY STUCK" Possible Cause: Damaged or shorted key/keypad. Start Note4 : Carefully peal off the affected keypad. Wipe the display surface with degreaser (Windex works well). Re-apply the keypad starting from one edge and using your fingers or a rag press the keypad in one direction to remove the air bubbles. Note 1: This code may occur when a user tried entering "Test Mode" or "Display Test Mode" using the wrong key. Look for any indentations on any of the keys. The plus or fast key are used most often and may cause this error. Note 2: Press and hold the "0", "2" & "START" keys down at the same time, then release the "2" key. The display will read: MAINTENANCE. Press and release the 5 key. Or manually hold the 5 key and simultaneously turn the treadmill on by the on & off switch. Reset the treadmill. Turn unit off, wait 2 seconds then retry. See (note 1) Code continues to display? YES Engage "ENGINEERING" mode. Verify keypad response in "Display Test". See (note 2) NO Stop YES Press each key. Verify that the display beeps and changes LED segments with every key on the display. All keys respond? YES NO Replace display panel. Note 3: If you are unable to enter the "ENGINEERING" or "Display Test", the panel may have a key that is permanently stuck. Replace the display panel. If any of the LED segments do not light up, there may be a failure in the electronics and you will need to replace the electronic board only. Note 4: Verify that the PWM LED is flashing, while the treadmill is on. The PWM LED indicates a valid control command is being sent from the Display Board to the PWM Board. If the LED is not flashing, check connection and look for pinch or tear marks. Does display engage Display mode? NO Replace display faceplate. See (note 3) Stop 4.34 Stop Stop

57 Code: NO STO Flowchart Definition: "NO STOP KEY" Possible Cause: Disconnected or shorted stop switch. Start 1A Note 1: Try pushing the emergency stop switch on & off. If switch appears to stick, replace stop switch assembly. Verify stop switch activation. See (note 1) Code continues to display? YES Note 2: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Press and release the 5 key. Does stop switch activate? YES NO NO Check stop switch connection in the handrail. Engage "ENGINEERING" mode. Verify keypad response in "Display Test". See (note 2) Turn the treadmill off. Remove the display panel and disconnect the emergency stop switch from the back of the display board. If connection is good, replace the stop switch assembly. If all or few keys do not respond, replace Display Board. Short the two pins on the display board together using either a jumper or paper clip. Stop Stop Turn the treadmill back on. 1A 4.35

58 Code: NO RPM Flowchart Definition: "RPM LOSS" Possible Cause: Damaged or misaligned RPM sensor. Start Note 1: Press and hold the "0", "1," & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Then press and release the 8 key. Or manually hold the 8 key and simultaneously turn the treadmill on by the on & off switch. Both methods will engage "Test mode". Note 2: Verify that the PWM LED is flashing, while the treadmill is on. The PWM LED indicates a valid control command is being sent from the Display Board to the M.C.B. If the LED is not flashing, check connection and look for pinch or tear marks on the display cable. Note 3: Verify that RPM feedback is being displayed under speed as the running belt moves. Note 4: To engage automatic speed calibration, press the "HEART" key. Display will read: CALI. Treadmill will then go into a self auto speed calibration. This will automatically calibrate MIN PWM, 1/2 max, and MAX PWM for min and max speed. This will take less than 3 minutes. Treadmill will be in motion, during this test. 1A NO Engage "MAINTENANCE" mode. Verify RPM feedback in "Test Mode". See (note 1) Display reads: XXX 3.0 (at 0%, XXX will read 240) Press the "+" and bring the middle number 3 up to 50. Does the running belt move? NO Left motor shroud and verify PWM LED for 110v units or MOTOR CONTROL LED for 220v units response. See (note 2) & Diagram #1 PWM LED responds? YES YES Does display read RPM feedback see (note 3)? YES Bring the speed back to.0 then engage automatic speed calibration. See (note 4) 1B Does unit auto calibrate? YES Stop NO NO Check the following: 1. RPM connection to J3 connector. 2. Check alignement. See (note 5) Diagram #2 & 3 2A 4.36

59 Code: NO RPM Flowchart 1A 2A Note 5: RPM Sensor gap between the Halll Effect pickup adn teh flywheel should be no more than 1/8 inch. If not, adjust the RPM sensor to correct gap. If no appearant damage is visable. Manually toggle the display cable for possible intermittent connection. If the PWM LED does not flash or intermittently respond, replace the display cable. Diagram #2 Process STOP Does display read RPM feedback? NO YES Replace RMP Sensor Engage automatic speed calibration. See (note 4) Stop Stop 4.37

60 Code: NO RPM Flowchart 1B Check the following connections; drive motor to choke/filter to MCB. Re-engage Test Mode. Bring speed command 3 back up to 50. Does the running belt move? NO YES Re-engage Auto- Calibration. See (note 4) By-pass the choke/filter from the MCB and drive motor. Stop Does the running belt move? YES NO Replace the choke/filter system. Replace the MCB Stop Stop 4.38

61 Definition: "SUDDEN SPEED CHANGE." Possible Cause: RPM pick-up misaligned. Code: SP CNG Flowchart Start Note 1: Press and hold the "0", "1", & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANC, then press and release the "8" key. Or, manually hold the "8" key and simultaneously turn the treadmill on by the on & off switch. Both methods will engage "Test Mode". Note 2: Verify that the PWM LED is flashing, while the treadmill is on. The PWM LED indicates a valid control command is being sent from the Display Board to the M.C.B. If the LED is not flashing, check connection and look for pinch or tear marks. Note 3: Adjust the potentiometer clockwise or counterclockwise. Engage "MAINTENANCE" mode. Verify RPM feedback in "Test Mode". See (note 1) Display reads: XXX 3.0 ( at 0%, XXX will read 240) Press the "+" and bring the middle number 3 up to 50. Does the running belt move? NO YES Does drive motor surge? YES Adjust the IRCOMP. See (note 3) Diagram #2 NO Diagram #1 Does display read RPM feedback see (note 4)? NO Note 4: Verify that RPM feedback is being displayed under speed as the running belt moves. Left motor shroud and verify PWM LED for 110v units or MOTOR CONTROL LED for 220v units response. See (note 2) Diagram #1 Does drive motor surge? YES NO YES 1C 1D 1A 1B 4.39

62 Code: SP CNG Flowchart 1A 1B Note 5: Turn the treadmill off and unplug. Remove one brush at a time. Check for unusual wear, replace if needed. LED responds? NO Manually toggle the display cable for possible intermittent connection. YES Replace the M.C.B. Check motor brushes, for unusual wear. See (note 5) Diagram #3 Brushes good? NO If the PWM LED does not flash or intermittently respond when cable is toggled, replace the display cable. Stop YES YES Treadmill runs smooth? Replace motor brushes. Then clear all error codes. (Note 8) NO Stop Diagram #2 1C 1D 110 Volt 220 Volt 4.40

63 Code: SP CNG Flowchart 1C 1D Note 6: To engage automatic speed calibration, press the "HEART" in Test Mode. The display will read: CALI. Treadmill will then go into a self auto speed calibration. This will automatically calibrate MIN PWM, 1/2 MAX, and MAX PWM for min and max speed. This will take less than 3 minutes. Treadmill will be in motion, during this test. Engage automatic speed calibration. See (note 6) Does unit auto calibrate? NO Check the following: 1. RPM connection to J3 connector. 2. Check alignement. See (note 7) Diagram # 4, 5, YES Note 7: The RPM sensor gap between sensor and flywheel is no more than 1/8 inch wide. If not, adjust the sensor. STOP Diagram #4 Diagram #3 Does display read RPM feedback? YES Engage automatic speed calibration. Then clear all error codes, see (note 8) NO Replace RPM sensor, or Hall effect depending on style.then clear all error codes, see (note 8) 4.41 Stop Stop

64 Code: SP CNG Flowchart Note 8: Engage "Maintenance Mode" Scroll up through the menu to the different error references by using the "UP" elevation key. Clear all error codes by pressing the "HEART" key. Diagram #5 Does display read RPM feedback? NO YES Engage automatic speed calibration. Exit "Test Mode" by pressing the stop key. Re-engage "Engineering Mode" and clear all error codes. See (note 8) Replace the RPM sensor or Hall Effect, depending on style. Then clear all error codes, see (note 8) Stop Stop 4.42

65 Definition: "ELEVATION LOST BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Code: EL LOST Flowchart Start Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Press and release the "8" key. Or manually hold the "8" key and simultaneously turn the treadmill on by the on & off switch. Both methods will engage "Test Mode". Note 2: When treadmill is at physical 0% the elevation range will read 240 across the display screen. Pressing the elevation "UP" key the elevation range number will decrease, 57 = 15% for 110v units, 80 = 15% for 220v units. Note 3: Engage MAINTENANCE mode scroll up through the menu to the different error references by using the "UP" elevation key. Clear all error codes by pressing the "HEART" key. Note 4: The elevation motor potentiometer may have failed or register the incorrect elevation value causing the motor to hesitate while operating. Using a Volt Meter, see diagram #1, use the chart in diagram #2 to instruct you in verifing the correct elevation values. Engage "TEST MODE" Verify elevation response in "Test Mode". See (note 1) Is incline within range See (note 2)? YES Clear display code. See (note 3) Stop NO If incline reading is less than 20 verify elevation motor potentiometer readings. See (note 4) If elevation motor readings register 0, check display cable for possible pinch or tear. Manually toggle the cable, if readings are now registered replace the display cable. If no readings are registered by toggling the display cable replace the elevation motor. Stop % Grade Incline number in Motor Test Mode DC Voltage across Blue and Orange wire on the Elev. motor connector Diagram #1 Ohm reading between the Blue and Orange (elev. motor unplugged) DC Voltage on Pin 4 of the display electronics k k k k k k k k k k k k k k k k 1.33 Diagram #2 4.43

66 Code: EL RNG Flowchart Definition: "ELEVATION RANGE BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Is incline greater than 240? YES NO Is incline less than 57 or 80? YES See (note 5) Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE/. Press and release the "8" key. Or manually hold the "8" key and simultaneously turn the treadmill on by the on & off switch. Both methods will engage "Test Mode". Note 2: In "TEST MODE" the number under "ELAPSED TIME" on the display, represents the elevation range. When physically at 0%, the range will register 240. When elevating the range will fluctuate from Elevation range 80 represents 15% for 220v units. 57 represents 15% for 110v units. Do not elevate beyond the range. Note 3: Exit out of TEST MODE. Re-ingage "MAINTENANCE Mode scroll through the menu using your elevation keys until display reads LST POT. The following variables store the condition when the last display code occurred. Note 4: Engage "MAINTENANCE Mode" scroll up through the menu to the different error references by using the "UP" elevation key. Clear all error codes by pressing the "HEART" key. Note 5: Thi would indicate that the elevation is within range and should be operating correctly, if not contact Unisen. Start Engage "TEST MODE" Verify elevation response in "Test Mode". See (note 1) Is incline within range. See (note 2)? YES Go to capture information. See (note 3) If LST POT registers , verify display cable connection. If connection is good replace the display cable. Stop NO Does elevation respond up & decrease range #? YES Elevate treadmill until display reads 240. Treadmill should physically be at 0%. Treadmill at 0% physically? Re-ingage regular mode. Verify if elevation is operating correctly. If elevation is working see (note 4) If display code continues contact Unisen YES Stop NO Proceed to EL STL flowchart. NO 1A NO Is treadmill above 15 %? YES Elevate treadmill down to 240. Elevation responds? YES Re-ingage regular mode. Verify if elevation is operating correctly. If elevation is working see (note 4) If display code continues contact Unisen. Stop NO 1B

67 Code: EL RNG Flowchart 1A 1B Disconnect the elevation motor belt and manually bring down the elevation until display read 240. Bring the treadmill down to physical 0% 240, using the elevation down key. Re-connect the elevation belt. Elevation responds? NO Re-ingage regular mode. Verify if elevation is operating correctly. If elevation is working see (note 4) If display code continues contact Unisen. YES Re-ingage regular mode. Verify if elevation is operating correctly. If elevation is working see (note 4) If display code continues contact Unisen. Proceed to EL STL flowchart. Stop Stop 4.45

68 Definition: "ELEVATION STALL BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Code: EL STL Flowchart Start Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Press and release the "8" key. Or manually hold the "8" key and simultaneously turn the treadmill on by the on & off switch. Both methods will engage "Test Mode". Engage "TEST MODE" Verify elevation response in "Test Mode". See (note 1) Note 2: Engage MAINTENANCE mode scroll up through the menu to the different error references by using the "UP" elevation key. Clear all error codes by pressing the "HEART" key. Does treadmill elevate in TEST MODE? YES NO Lift motor shroud. Verify elevation "UP" & "DOWN" LED's toggle when elevation keys are being pressed. See diagram #1 NO Diagram #1 Replace Display Cable. Note 3: Visually check both fuses. Replace fuses, if burned or cracked. If a multi-meter is available, verify continuity. Clear display code. Do elevation LED's toggle? YES Stop Stop Check fuses 1 & 2 on the M.C.B. See (note 2) Replace fuses. NO Fuses good? Verify elevation screws are being lubricated and no foriegn obsructions are binding the elevation system. YES A Stop

69 Code: EL STL Flowchart 1A Note 4: Diagram #2 Place your (red) meter probe into the black wire of pin 4, located at connector J5. Then place your (black) meter probe to AC1 on the M.C.B. Voltage should read +/-110v. or +/-220v depending on model. When pressing the elevation "DOWN" key, the voltage should drop down to 0v or 1v. This would indicate a good response from the M.C.B. Do the same for pin 5 (red wire), as shown in Diagram #4. Then press the elevation "UP" key. Voltage should drop down to 0v or 1v. Using a multi-meter, verify voltage at the following pins (4&5) from the Elevation Motor connector J5. See (note 4) Diagram #2 & 3 Does voltage change at pins 4 & 5? YES Replace the Elevation Motor. Then clear all error codes, see (note 3) NO Replace the M.C.B. Then clear all error codes, see (note 5) Stop Stop Diagram #2 4.47

70 Section 5: Parts Replacement Should the STAR TRAC 4500 Treadmill experience a problem requiring replacement of a specific part, the following procedures will help and instruct in the replacement of major parts. Contents Drive Motor Replacement Auto-transformer Replacement Elevation Motor Replacement Heart Rate Grip Replacement Side Bed Cover Replacement 5.0

71 Drive Motor Replacement ** CAUTION ** Always turn the power switch to the off position. Unplug the treadmill power cord from the power outlet. Tools: Running Belt Drive Motor Philips-head screwdriver Bungee cord, approx. 24 inches Needle nose pliers 5/16-in socket and torque socket wrench to measure 110 in/lb. 1/8-in. Allen torque wrench to measure 75 in./lb. Plastic hammer Punch Straight edge, 24 inch Belt Tension Gauge, to 90 lbs. (optional) Procedure: Lift motor shroud The drive motor is located below the plastic shroud at the front of the treadmill. To remove the shroud at access the motor, proceed as follows: 1. Remove the Philips-head screw at the center of the front edge of the shroud. 2. Lift up the front of the shroud, lifting from both sides to separate the Velcro strips. 3. Lift the shroud up the vertical rails as far as it can go, then suspend it using a bungee cord looped over the gooseneck rail and hooked up under the upper edge of the shroud. The drive motor is now accessible for replacement. Disconnecting Motor Wiring 1. Follow the green ground wire from the motor to the grounding point in the frame (marked with the ground symbol), then remove the screw that hold the wire terminal to the frame. 2. Cut the two wire ties that hold together the remaining wiring from the motor. 3. Using needle nose pliers, pull apart the black plug-in connector of the red and black wires. Do not pull on the wires. 4. Follow the gray sensor cable to the connector marked J# on the left end of the circuit board, and pull the cable connector upwards to disconnect it from the board. 5.1